Assembly for preventing water damage to insulated exhaust ducts

ABSTRACT

An exhaust vent cap assembly can be installed in a roof deck of a building to allow a one-time connection of the insulated duct to the roof from exhaust fans within the building.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of a U.S. Pat. ApplicationSer. No. 17/316,414, filed on May 10, 2021, which claims priority from aU.S. provisional Pat. Application serial number 63/146,944, filed onFeb. 08, 2021, both of which are incorporated herein by reference in itsentirety.

FIELD OF INVENTION

The present invention relates to an exhaust vent cap assembly, and moreparticularly, the present invention relates to an exhaust vent capassembly for preventing water damage to insulated exhaust ducts and fanassembly of a ventilation system in a building.

BACKGROUND OF INVENTION

As part of the ventilation system of a house, exhaust fans are installedin bathrooms or toilets to remove the odor and moist air to the outsideof the house. Fans are usually installed in the ceiling of bathrooms toegress exhaust air. A small duct is connected to the fan and runsthrough space between floors or in the attic to vent air to the outside.The ducts end in the roof deck or outside walls of a building. The roofdeck is prepared for installing the duct by making a round hole of thesize proportional to the size of the duct either on the outer wall ofthe house or in the roof deck for the air to exhaust to the outside(called, penetration).

Roofer later installs a waterproof cap over the hole where the duct isattached, to waterproof the penetrations. In colder climates, the moistair running through the round duct to the outside can condensate andwater will drip down to the fan assembly in the ceiling of the bathroomor where the fan is installed and cause damage. To avoid condensationissues, ducts are insulated. To ease installation, round flexible ductswith insulation around them, also known as flex ducts, are used inconnecting the fans to the roof culler.

During construction of a building, the HVAC company installs the fans inthe ceilings and makes a round hole in the plywood (roof deck) andattaches the duct to a piece of round steel tube and attaches the roundtube to underneath the roof deck in front of the hole on the roof. Theround tube is secured to the roof deck with few metal-sheet strips. Thehole is open to the outside air for the rain to get into the duct.

In the normal course of construction, the HVAC personnel are the firsttrade to work on the house once the house is framed. The plumber andthen electrician come after HVAC workers and other trades follow them.Roofers install the roof when HVAC personnel and plumbers have made thepenetrations and done with their work. Therefore, the holes that HVACpersonnel make on the roof are open to the atmosphere till the rooferscome and install the permanent cap over the holes.

There could be a one- or two-weeks gap or even sometimes more till theholes on the roof can be covered by the permanent caps. During suchtime, rain or snow often comes and water travels down the open holetoward the fan and brings water inside the house, and also damages theinsulation around the duct attached to the fan.

The HVAC personnel must come back and replace the ducts that were soakedwith water and deemed useless. With a typical house having two-threevents through the roof, the cost of replacing the flexible duct or theinsulation around the ridged duct can get expensive. Since these ductsare in the attic, workers must maneuver between the roof trusses andframe members to make the holes and attach the roof collar. This makesthe work even more challenging and labor-intensive. The additionalmaterial and labor with the trip to make the repairs add to theoperational expense of the HVAC Company, chipping away at their profits.This phenomenon happens repeatedly and often enough that the cost of theadditional repairs becomes substantial.

Both the consumers and the industries have a desire for a solution tothe aforesaid problems.

SUMMARY OF THE INVENTION

The following presents a simplified summary of one or more embodimentsof the present invention in order to provide a basic understanding ofsuch embodiments. This summary is not an extensive overview of allcontemplated embodiments and is intended to neither identify key orcritical elements of all embodiments nor delineate the scope of any orall embodiments. Its sole purpose is to present some concepts of one ormore embodiments in a simplified form as a prelude to the more detaileddescription that is presented later.

The principal object of the present invention is therefore directed toan exhaust vent cap assembly for preventing damage to insulated exhaustducts.

It is another object of the present invention that the assembly preventslabor, cost, and time for replacing the damaged ducts.

It is still another object of the present invention that the assemblyprevents undesired alterations in the building for replacing the damagedinsulated exhaust ducts.

It is a further object of the present invention that the assembly iseasy to install.

It is yet another object of the present invention that the assembly iseconomic to manufacture.

In one aspect, disclosed is an exhaust vent cap assembly that can beinstalled in a roof deck of a building to allow onetime connection ofthe insulated duct to the roof from exhaust fans within the building.

In one aspect, disclosed is an exhaust vent cap assembly comprising atubular body, the tubular body comprising a hollow tube having aproximal end and a distal end, a flange extends around a periphery ofthe proximal end perpendicularly to the hollow tube, and a mouthupstanding from the proximal end of the hollow tube; and a capconfigured to sealably fasten to the mouth, the cap and the mouth havinga fastening mechanism, wherein an outer diameter of the cap issubstantially same as an outer diameter of the mouth. The mouth and thehollow tube are integral, and the flange is mechanically attached. Theflange and the hollow tube are integral, and the mouth is mechanicallyattached. The flange and the mouth are integral, and the hollow tube ismechanically attached. The hollow tube, the mouth, and the flange areintegral. The cap and the mouth are having threads for securing the capto the mouth, the cap is having a handle for turning the cap. The capand the mouth are configured for snap-fitting the cap onto the mouth.The cap is having a furrow as a handle for lifting the cap. The cap andthe mouth are configured for a friction fit.

In one aspect, disclosed is an exhaust vent cap assembly comprising atubular body, the tubular body comprising a hollow tube having aproximal end and a distal end, a flange extends around a periphery ofthe proximal end perpendicularly to the hollow tube, and a mouthupstanding from the proximal end of the hollow tube; a cap configured tosealably fasten to the mouth, the cap and the mouth having a fasteningmechanism, wherein an outer diameter of the cap is substantially same asan outer diameter of the mouth; and a duct, the duct has a proximal endand a distal end, the proximal end of the duct is coupled to the distalend of the hollow tube.

These and other objects and advantages of the embodiments herein and thesummary will become readily apparent from the following detaileddescription taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying figures, which are incorporated herein, form part ofthe specification and illustrate embodiments of the present invention.Together with the description, the figures further explain theprinciples of the present invention and to enable a person skilled inthe relevant arts to make and use the invention.

FIG. 1 is a perspective view of the disclosed exhaust vent cap assembly,according to an exemplary embodiment of the present invention.

FIG. 2 is an exploded view showing the cap and the tubular body of thedisclosed exhaust vent cap assembly, according to an exemplaryembodiment of the present invention.

FIG. 3 is a side planar view of the exhaust vent cap assembly, accordingto an exemplary embodiment of the present invention.

FIG. 4 is a sectional view of the exhaust vent cap assembly taken alongthe line 8-8 of FIG. 3 , according to an exemplary embodiment of thepresent invention.

FIG. 5 is a bottom view of the exhaust vent cap assembly, according toan exemplary embodiment of the present invention.

FIG. 6 is an exploded perspective view of another exemplary embodimentof the exhaust vent cap assembly, according to the present invention.

FIG. 7 is a perspective view of another exemplary embodiment of theexhaust vent cap assembly, according to the present invention.

FIG. 8 is a side view of the exhaust vent cap assembly shown in FIG. 7 ,according to an exemplary embodiment of the present invention.

FIG. 9 is a sectional view of the exhaust vent cap assembly taken alongthe line 27-27 shown in FIG. 8 , according to an exemplary embodiment ofthe present invention.

FIG. 10 shows the exhaust vent cap assembly installed in a roof deck andconnected to a duct, according to an exemplary embodiment of the presentinvention.

FIG. 11 shows a flange of the exhaust vent cap assembly that hasapertures with sealed knockouts, according to an exemplary embodiment ofthe present invention.

FIG. 12 is a sectional view of the exhaust vent cap assembly with a tieto secure the duct, according to an exemplary embodiment of the presentinvention.

FIG. 13 shows another embodiment of the exhaust vent cap assembly for awall, according to an exemplary embodiment of the present invention.

DETAILED DESCRIPTION

Subject matter will now be described more fully hereinafter withreference to the accompanying drawings, which form a part hereof, andwhich show, by way of illustration, specific exemplary embodiments.Subject matter may, however, be embodied in a variety of different formsand, therefore, covered or claimed subject matter is intended to beconstrued as not being limited to any exemplary embodiments set forthherein; exemplary embodiments are provided merely to be illustrative.Likewise, a reasonably broad scope for claimed or covered subject matteris intended. Among other things, for example, the subject matter may beembodied as methods, devices, components, or systems. The followingdetailed description is, therefore, not intended to be taken in alimiting sense.

The word “exemplary” is used herein to mean “serving as an example,instance, or illustration.” Any embodiment described herein as“exemplary” is not necessarily to be construed as preferred oradvantageous over other embodiments. Likewise, the term “embodiments ofthe present invention” does not require that all embodiments of theinvention include the discussed feature, advantage, or mode ofoperation.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of embodiments ofthe invention. As used herein, the singular forms “a”, “an” and “the”are intended to include the plural forms as well, unless the contextclearly indicates otherwise. It will be further understood that theterms “comprises”, “comprising,”, “includes” and/or “including”, whenused herein, specify the presence of stated features, integers, steps,operations, elements, and/or components, but do not preclude thepresence or addition of one or more other features, integers, steps,operations, elements, components, and/or groups thereof.

The following detailed description includes the best currentlycontemplated mode or modes of carrying out exemplary embodiments of theinvention. The description is not to be taken in a limiting sense but ismade merely for the purpose of illustrating the general principles ofthe invention, since the scope of the invention will be best defined bythe allowed claims of any resulting patent.

Disclosed is an exhaust vent cap assembly for a ventilation system of abuilding. The disclosed exhaust vent cap assembly secures the insulatedexhaust ducts of the ventilation system to the roof deck or outer wallof the building. Disclosed exhaust vent cap assembly eliminates theredundant work and the extra costs associated with replacing theinsulated exhaust ducts in the attic that are damaged by water andstopping water from entering the house through the exhaust fans.

Referring to FIG. 1 , which shows the disclosed exhaust vent capassembly 100 having a cap 110 and a tubular body 120. FIG. 2 is anexploded view of the exhaust vent cap assembly 100 showing the cap 110separated from the tubular body 120. The tubular body 120 having acylindrical hollow tubular body 130 that is rigid and made of durablematerial. The cylindrical hollow tubular body 130 having a proximal endand a distal end. Around the periphery of the proximal end of thecylindrical hollow tubular body 130 extends a flange 140 perpendicularto the cylindrical hollow tubular body 130. The flange 140 can be usedto secure the disclosed exhaust vent cap assembly 100 to the roof deckor the outer wall. The flange 140 can be welded to the tubular body 130or can be continuous with the wall of the tubular body. At the proximalend of the tubular body can be seen a mouth 150 of the tubular body 120.The mouth and the cap can have a fastening mechanism for securing thecap to the mouth. The cap sealably engages with the mouth 150 of thetubular body 120 to prevent the ingress of water into the tubular bodyand the ducts. FIG. 2 shows the cap and the mouth having correspondingthreads 160 and 170 for securing the cap 110 to the mouth. FIG. 3 is aside planar view and FIG. 4 is a sectional view showing the cap securedto the mouth wherein the threads of the cap are engaged to the threadsof the mouth of the tubular body. A ridge 190 can also be seen in FIG. 4which helps in retaining the duct over the tubular body. FIG. 5 is abottom view of the tubular body 120 showing the hollow cylindricaltubular body. The cap can also include a handle 180 for turning the cap110 over the mouth 150 of the tubular body 130.

The fastening mechanism and the handle can be varied for desired watertightness. FIG. 2 shows the roof cap assembly having the screwmechanism. The screw mechanism can be replaced by the snap-fitmechanism. FIG. 6 shows the assembly 200 having the cap and mouth,wherein the cap can be snap-fit over the mouth of the tubular body. Thecap can be plane from inside, wherein vertical ridges 210 are shown onan outer surface of the mouth. The vertical ridges around the mouth canbe replaced by horizontal ridges that surround the mouth. The top of thecap is planar and may not have any handle.

FIG. 7 shows another exemplary embodiment of the exhaust vent capassembly 300, wherein the cap 305 is having a furrow 310 which can actas a handle for lifting the cap 305. FIG. 8 is a side view of theexhaust vent cap assembly 300. FIG. 9 is a cross-sectional view of theexhaust vent cap assembly shown in FIG. 8 taken along line 27-27. Thetubular body can have circling recess 320 which engages with a dimple330 in the outer wall of the cap 305. This assembly can be made from avariety of materials, such as plastics, metal, composite materials, etc.The shape of the cap and handle can be varied. Similarly, any fasteningmechanism for sealably securing the cap to the tubular body is withinthe scope of the present invention.

The removable cap can have different shapes to achieve water tightness.It can be snapped onto the top of the tubular member. It can also be ashape of a lid that goes over the tube having friction fit, a cap thatcan be screwed onto the tubular member by fasteners, or other methods ofsecuring the cap to the tubular member so it is not easily removed bywind. All these methods are meant to produce a waterproof assembly sowater may not be able to seep inside the insulated ducts.

FIG. 10 shows the exhaust vent cap assembly installed on an underside ofa roof deck 430 and secured to the duct 400 of the ventilation system.First, a hole can be made in the roof deck 430. The diameter of the holein the roof deck can be the same as the external diameter of the mouthof the tubular body 410, such as the mouth can slide into the hole. Themouth is inserted into the hole while the flange 420 rests against theunderneath of the roof deck 430. The flange 420 can then be secured tothe roof deck using fasteners. The mouth of the tubular body can extendabove the roof surface. Cap 450 can be secured to the mouth forpreventing the ingress of water into the duct.

The duct 400 can be pushed onto the distal end of the tubular body andsecured using fasteners 440 and/or a strap. A tubular body can have aprotrusion 460 that further prevents the slipping of the duct over thetubular body. An instruction label will be affixed or printed on the capfor a roofer to remove before they install the permanent roof cap 470.

Alternatively, this disclosed exhaust vent cap assembly can also beattached to one end of the exhaust duct in a factory for ease ofinstallation in the field. All the installer has to do is to make a holein the roof deck, as usual, insert the device through the hole and screwthe flange with a few fasteners underneath the roof deck and connect theother end to the exhaust fan. Roofers can remove the removable cap laterwithout the chance of water entering the house or damaging the ductinsulation.

The different components of the disclosed exhaust vent cap assembly canbe made of different materials, such as virgin or recycled plastics,sheet metal, metal casting, PVC, or any material that is commonly used.

Referring to FIG. 11 shows an exemplary embodiment of a cylindricalhollow tubular body 1100 with a flange 1110. The flange 1110 has holes1120 that are sealed by one or more knockouts 1130. The knockouts 1130can be broken to gain access through the holes 1120. Insulation foam canbe delivered through the holes, such as a tip of a foam insulating toolcan be inserted into the holes for applying foam insulation. The foaminsulation can fill in any gaps created by drilling holes in the roof orthe wall. For example, the diameter of the hole drilled in a structurefor installing the vent can be larger than the tubular body of thedisclosed assembly. The space between the structure and the tubular bodycan be filled with insulation foam. The knockout can sealably cover theholes and can be of a thin profile that can be broken, such as using asharp object. For example, plastic can be used for knockouts that caneasily rupture. When using metal for the knockouts, perforation in theperiphery or a similar line of weakness can be provided.

The above embodiments describe the assembly for use in roof vents,however, the disclosed assembly can also be adapted for vents in thewall. Vents can be provided on the walls of a building, in particular,multistory buildings, such as multi-family dwellings, offices, orcommercial places. Currently, the exhaust vents that are inside thebuilding envelope for bathroom fans, dryers, or other equipment thatneed exhaust vents to outside are commonly placed in the band boards,exterior walls, attic gable ends, or roof area. Typically, a hole forthe vent is drilled in the perimeter of the house and through the bandboard. Band boards are usually a wood product that covers the ends ofthe floor joists. The hole for the vent can also be made in the exteriorsheeting or bandboard. The disclosed exhaust vent assembly can beadapted for such wall vent holes. Advantage of the disclosed ventassembly in the side mount applications is that it can be installed frominside the house instead of outside as it is currently done. Thus,making installation of the vent assembly much easier. FIG. 12illustrates an exhaust vent assembly 1200 that includes a cap 1210 and atubular body 1220. The tubular body is a cylindrical hollow tubular bodythat is rigid and made of durable material. The cylindrical hollowtubular body has a proximal end and a distal end. Around the peripheryof the proximal end of the cylindrical hollow tubular body is a flange1225 that extends perpendicular to the cylindrical hollow tubular body.The flange can be used to secure the disclosed exhaust vent cap assemblyto a band board 1230. At the proximal end of the tubular body can beseen a mouth 1260 of the tubular body. The exhaust vent assembly adaptedfor mounting to a wall vent can be similar to the above-describedexhaust vent assembly in FIGS. 1-10 and thus the details are notrepeated herein.

For installation, the tubular body can be inserted into the vent hole.The duct 1240 extending from the vent of the room’s exhaust system canbe coupled to the tubular body of the disclosed assembly and the cap canbe secured. Alternatively, the cap can be pre-secured to the mouth. Inanother implementation, the duct can be a part of the disclosedassembly, wherein the duct, the tubular body, and the cap can bepre-assembled i.e., the cap is secured to the mouth and the duct issecured to the tubular body. The free end of the duct can be coupled tothe fan 1250. The cap is accessible from outside of the wall and can beremoved later and a permanent cap can be placed over the vent hole. Thedisclosed assembly with or without the duct can be installed from insideof the wall. Perhaps, installing from inside can be safer avoiding theneed for climbing tall ladders thus addressing the fall or injuryconcerns using tall ladders or complications associated withinstallation from outside. Moreover, installing from inside the wall canbe easier and quicker. A tie strap 1270 can secure the duct mounted overthe tubular body.

For Installation, a hole can be drilled in an exterior sheeting of astructure from the inside. Then the tubular body with the cap secured tothe mouth can be inserted from the inside and the flange of the tubularbody can be secured using multiple fasteners, such as screws. Theflexible duct may already be attached to the tubular body or can beattached to the tubular body. The free end of the duct can be extendedto the fan of the ventilation system. The removable and disposable capof the disclosed exhaust vent assembly can seal the vent hole preventingingress of dust and water. Upon finishing the exterior of the wall(structure), the cap of the disclosed exhaust vent assembly can beremoved, and a permanent cap of choice can be installed. The temporarycap can be designed in several ways as shown in FIGS. 1-10 .

Referring to FIG. 13 shows an exemplary embodiment of the disclosedexhaust vent assembly 1300. The exhaust vent assembly 1300 includes atubular body 1310, the tubular body has a mounting flange 1320 andremovable cap 1330 coupled to the mouth 1340. The tubular body 1310 hasa rim-like profile that can receive a flexible duct, the tubular bodyhas protrusions to prevent the flexible duct from slipping out. Also, azip tie 1360 is shown wrapped around the duct tightening the duct aroundthe tubular body. The flexible duct can also be taped to the tubularbody using foil tape or other adhesives appropriate for thisapplication. Instead of flexible ducts, rigid ducts can also be used andare within the scope of the present invention. For a rigid duct, the endof the tubular body can be tapered inwards so that the duct can easilygo over the sleeve of the tubular body.

In one implementation, the length of the tubular body can be made ofdifferent sizes to allow for various thicknesses in the framingstructures. The length of the tubular body and its diameter is ofsufficient size to allow ease of use. This invention is designed to fitvarious sizes of flexible or rigid ducts in the market, such as 4", 6",8", 10", or any other conceivable size. Rigid ducts are typically madeof sheet metal and flexible ducts with plastic tubes with wirereinforcement having outer insulation and some are made of aluminum.

While the foregoing written description of the invention enables one ofordinary skill to make and use what is considered presently to be thebest mode thereof, those of ordinary skill will understand andappreciate the existence of variations, combinations, and equivalents ofthe specific embodiment, method, and examples herein. The inventionshould therefore not be limited by the above-described embodiment,method, and examples, but by all embodiments and methods within thescope and spirit of the invention as claimed.

What is claimed is:
 1. An exhaust vent cap assembly comprising: atubular body, the tubular body comprising: a hollow tube having aproximal end and a distal end, a flange extends around a periphery ofthe proximal end perpendicularly to the hollow tube, and a mouthupstanding from the proximal end of the hollow tube; and a capconfigured to sealably fasten to the mouth, the cap and the mouth havinga fastening mechanism, wherein an outer diameter of the cap issubstantially same as an outer diameter of the mouth.
 2. The exhaustvent cap assembly according to claim 1, wherein the mouth and the hollowtube are integral, and the flange is mechanically attached.
 3. Theexhaust vent cap assembly according to claim 1, wherein the flange andthe hollow tube are integral, and the mouth is mechanically attached. 4.The exhaust vent cap assembly according to claim 1, wherein the flangeand the mouth are integral and the hollow tube is mechanically attached.5. The exhaust vent cap assembly according to claim 1, wherein hollowtube, the mouth, and the flange are integral.
 6. The exhaust vent capassembly according to claim 1, wherein the cap and the mouth are havingthreads for securing the cap to the mouth, the cap is having a handlefor turning the cap.
 7. The exhaust vent cap assembly according to claim1, wherein the cap and the mouth are configured for snap-fitting the caponto the mouth.
 8. The exhaust vent cap assembly according to claim 7,wherein the cap is having a furrow as a handle for lifting the cap. 9.The exhaust vent cap assembly according to claim 1, wherein the cap andthe mouth are configured for a friction fit.
 10. An exhaust vent capassembly comprising: a tubular body, the tubular body comprising: ahollow tube having a proximal end and a distal end, a flange extendsaround a periphery of the proximal end perpendicularly to the hollowtube, and a mouth upstanding from the proximal end of the hollow tube; acap configured to sealably fasten to the mouth, the cap and the mouthhaving a fastening mechanism, wherein an outer diameter of the cap issubstantially same as an outer diameter of the mouth; and a duct, theduct has a proximal end and a distal end, the proximal end of the ductis coupled to the distal end of the hollow tube.
 11. The exhaust ventcap assembly according to claim 10, wherein the mouth and the hollowtube are integral, and the flange is mechanically attached.
 12. Theexhaust vent cap assembly according to claim 10, wherein the flange andthe hollow tube are integral, and the mouth is mechanically attached.13. The exhaust vent cap assembly according to claim 10, wherein theflange and the mouth are integral and elongated cylindrical hollow tubeis mechanically attached.
 14. The exhaust vent cap assembly according toclaim 10, wherein the hollow tube, the mouth, and the flange areintegral.
 15. The exhaust vent cap assembly according to claim 10,wherein the cap and the mouth are having threads for securing the cap tothe mouth, the cap is having a handle for turning the cap.
 16. Theexhaust vent cap assembly according to claim 10, wherein the cap and themouth are configured for snap-fitting the cap onto the mouth.
 17. Theexhaust vent cap assembly according to claim 16, wherein the cap ishaving a furrow as a handle for lifting the cap.
 18. The exhaust ventcap assembly according to claim 10, wherein the cap and the mouth areconfigured for a friction fit.